Method and apparatus for cutting low density flexible material using a rotary cutting tool

ABSTRACT

Apparatus and method for cutting a low density flexible material and passing through a semi-rigid base material simultaneously by means of a rotary milling cutter and simultaneously applying a compressive force to the flexible material to increase the rigidity of the flexible material while cutting the flexible material, the method includes passing the cutter through a part of the semi-rigid material. The compression force is applied by a partial cylindrical shaped compression head having the rotary milling cutter extending therethrough.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. ProvisionalApplication Ser. No. 60/168,520 filed Dec. 2, 1999.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable

BACKGROUND OF THE INVENTION

[0003] This invention relates generally to a method and apparatus forcutting through low-density flexible material such as non-rigidfiberglass duct-liner insulation by pre-compressing the material using arotary cutting milling tool to cut the material and supporting thematerial on a semi-rigid base that allows the milling tool to passthrough it with minimal damage to the base.

[0004] Applicant is aware of the following U.S. Pat. Nos.: 4,880,958;4,792,657; 5,044,235; 5,208,440; and, 5,460,067. None of the abovepatents relate to pre-compression of a flexible material and cutting itwith a rotary cutting tool.

BRIEF SUMMARY OF THE INVENTION

[0005] The invention incorporates a spherical density conversion head tocompress the flexible material to convert it to a higher density.

[0006] The problems of cutting low-density non-rigid material such asfiberglass insulation by use of a spherical density conversion head anda rotary cutting milling tool are not solved by the prior art. Anapparatus and method is disclosed herein for cutting sheets of non-rigidmaterial such as fiberglass duct-liner insulation for air conditioningand the like is carried out by converting the non-rigid material to asemi-rigid material through compression, prior to cutting. According tothe preferred embodiment of the invention, sheets of a low densitysemi-rigid artificial turf material, such as shown in U.S. Pat. Nos.3,935,352; 3,940,522; 4,007,307; 4,426,415; and 5,601,886, are placed ona table of a milling machine and a sheet of, or sheets of a low densityflexible material are placed on the low density semi-rigid artificialturf material. The sheets of low-density flexible material are thencompressed to a semi-rigid state in the region where they are to be cutor milled.

[0007] The downward pressure of the machine compresses the flexiblefiberglass duct liner insulation to a semi-rigid and non-tangled stateand the semi-rigid materials may be cut or milled simultaneously whenpressing the material.

[0008] It is an object of the present invention to provide an improvedmethod of simultaneously cutting flexible low-density fiberglassduct-liner insulation by converting the low density material to asemi-rigid state and cutting the material by means of a rotary millingcutting.

[0009] It is another object of the present invention to compress afibrous or flexible material and cut the compressed material by means ofa rotary cutter.

[0010] It is another object of the present invention to provide animproved process of cutting flexible materials by compressing thematerial and simultaneously cutting the material by means of a rotarycutter in combination with a vacuum system for waste materialcollection.

[0011] It is another object of the present invention to provide animproved machine for cutting flexible materials.

[0012] With the above and other objects in view, the present inventionconsists of the combination and arrangement of parts hereinafter morefully described, illustrated in the accompanying drawing and moreparticularly pointed out in the appended claims, it being understoodthat changes may be made in the form, size, proportions and minordetails of construction without departing from the spirit or sacrificingany of the advantages of the invention.

BRIEF DESCRIPTION OF THE DRAWING(S)

[0013]FIG. 1 is an isometric view of a machine that may be used for thepressing, milling and cutting of flexible material according to theinvention.

[0014]FIG. 2 is an isometric view of a machine that may be used for thepressing, milling and cutting of flexible material with the use ofmultiple cutting heads mounted on a raise able hinged gantry.

[0015]FIG. 3 is an enlarged view of the density conversion head and therotary milling machine with the drive motor and controller.

[0016]FIG. 4 is an enlarged partial side view of a rotary milling cutterin combination with a spherical density conversion head according to theinvention.

[0017]FIG. 5 is an isometric view of the semi-rigid material of theartificial turf.

[0018]FIG. 6 is an enlarged cross sectional view of the combinationrotary milling tool and a perforated spherical density conversion headadapted to compress the flexible material, in combination with a hoseconnection to apply a vacuum to collect waste material during thecutting operation in accordance with the invention.

[0019]FIG. 7 is a bottom view of the perforated spherical densityconversion head.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

[0020] The preferred embodiment of the invention is illustrated by wayof example in FIGS. 1 and 2 which show machine 10 for simultaneouslycutting low density flexible fiberglass duct-liner insulation 24 andpassing through low density semi-rigid material 36. Low densitysemi-rigid material 36 may be artificial turf-type material of the typeshown in U.S. Pat. No. 4,007,307. The cutting is done by rotary millhead 11, which holds cylindrical rotary machine cutter 20 driven bymotor 12 through shaft 16. Motor 12 is connected by cable 15 to powersource 14. Cylindrical rotary milling machine cutter 20 has cuttingteeth 21 that extend outwardly on outer diameter 25 and come to a sharppoint 23. Conversion head 18 is mounted to rotary mill head 11.Conversion head 18 has partial spherical surface 22 having a center ofcurvature on the axis of rotation of rotary milling machine cutter 20.One or more rotary milling heads 11 are supported on one or more lateraltracks 30.

[0021]FIG. 2 shows a machine having two lateral tracks 30 joined bycross members 31 forming a raise and lower able gantry 33 which is shownin both the raised position A for convenient placement of materials andlowered position B ready for operation of rotary milling heads 11.Gantry 33 has hinges 19 mounted at one end of each lateral track 30.Lateral track 30 has driving means 32 for movement of rotary millingheads 11, on which is mounted conversion head 18. Lateral track 30either as a single track or as a unit of two forming gantry 33 can bemoved longitudinally on tracks 34 mounted to table 26.

[0022] Conversion head 18 engages insulation 24 and compresses it toform a thin semi-rigid region 38 of insulation material 24 that isengaged by rotary milling machine cutter 20 so that the fibers ofinsulation 24 will be held in place and will be cut by rotary millingmachine cutter 20 as the rotary milling head or heads travel alonglateral track 30 or gantry 33 which in turn can travel alonglongitudinal track 34.

[0023] The preferred embodiment of the invention is illustrated by wayof example in FIGS. 3 through 7 which show machine cutter 20, which isrotated by shaft 16 attached to motor 12 which is mounted on rotary millhead 11, whose cutting teeth 21 and sharp point 23 simultaneously cutlow density flexible fiberglass duct liner insulation 24 in the thinsemi-rigid region 38 and pass through low density semi-rigid material36, mounted on table 26, whose turf blades 27 support insulation 24while it is being pressed on by spherical conversion head 18 having apartial spherical lower surface 22. Teeth 21 on milling cutter 20 willdeflect turf blades 27 and pass between them doing very little or nocutting or milling damage to them. Vacuum ports 17 in partial sphericalsurface 22 on conversion head 18, will allow movement of air through theinterior formed by conversion head lid 28 when vacuum hose connection 29is attached to a vacuum cleaner or other air movement device. Thisairflow will pick up and carry away waste material 35 produced by thecutting action of rotary cutter teeth 21 as they pass through the thinsemi rigid section of insulation 24.

[0024] In the method of the invention low density flexible duct linerinsulation 24 is placed on top of a low density semi-rigid material,such as artificial turf 36 as shown in FIG. 5, having grass like fibersor blades 27 that extend laterally, longitudinally and vertically atrandom, which move aside as rotary milling machine cutter 20 movesthrough the turf without cutting a substantial amount of the blades orfiber and protecting table 26 on which the semi-rigid material 36 isplaced. Thus, low-density flexible duct liner insulation 24 is cut andmay be removed from the system. Low-density semi-rigid material 36 maybe removed or allowed to remain on table 26. A new sheet of low densityflexible duct liner insulation 24 may be loaded on top of low densitysemi-rigid material 36 and cut as previously described.

[0025] The foregoing specification sets forth the invention in itspreferred, practical forms but the structure shown is capable ofmodification within a range of equivalents without departing from theinvention which is to be understood is broadly novel as is commensuratewith the appended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. A method of cutting alow-density flexible sheet material comprising the steps of: supportingsaid flexible sheet material on a semi-rigid base; compressing saidflexible material to substantially a rigid state; and, cutting saidcompressed flexible sheet material with a rotary cutter that passesthrough said compressed flexible sheet material and at least a portionof said semi-rigid base simultaneously.
 2. The method of claim 1comprising the further step of providing a rotary milling cutter havingan axis of rotation generally perpendicular to said sheet.
 3. The methodof claim 1 further comprising the further step of providing a conversionhead having a surface concentric to said axis of rotation of saidcutter.
 4. The method of claim 3 further providing said conversion headwith the shape of a section of a sphere.
 5. The method of claim 4further providing a lid on the top of and vacuum ports in the lowerportion of, said section of a sphere, through which airflow is inducedto remove waste material produced by said cutter.
 6. The method of claim1 providing said flexible material having the characteristics offiberglass insulation having fibers; and, compressing together saidfibers prior to cutting.
 7. The method of claim 1 further providing saidsemi-rigid base material as an artificial turf-like material.
 8. Themethod of claim 7 further providing upwardly extending blades on saidartificial turf-like material blades extending upward from said flexiblesheet material.
 9. The method of claim 7 further providing upwardly andlaterally extending spaced grass-like fibers on said flexible material.10. The method of claim 9 further providing spacing said grass-likefibers from one another.
 11. The method of claim 9 further providinginclining some of said grass-like fibers at about 60 degrees to asurface supporting said material.
 12. A method of cutting a low densityfiber material comprising placing a layer of low-density flexiblematerial on a support surface; and, compressing said low-densityflexible material to a substantially rigid state and cutting saidmaterial with a rotary cutter.
 13. The method of claim 12 furtherproviding said rotary cutter with teeth having cutting edges disposed ina cylindrical path.
 14. The method for claim 12 further providing apoint on a distal end of said cutter.
 15. A machine for simultaneouslycutting low density flexible material and passing through low densitysemi-rigid material comprising a rotary cutting tool, rotating around avertical axis; a compressive force means applied to said low densityflexible material, having a partial spherical conversion head having anaxis concentric to the rotation of the rotary milling tool; and, a firstmeans on said machine to move said cutting tool in a lateral directionand a second means to move said tool in a longitudinal direction to cutsaid material into pieces.
 16. The machine recited in claim 15 whereinsaid cutting tool has teeth disposed in a generally cylindrical patternand extending radially outward.
 17. The machine recited in claim 15wherein said conversion head is moved in a vertical direction therebycompressing said flexible material outward from said axis of rotation.18. A machine for cutting sheets of low-density fiberglass material;said machine having two laterally spaced tracks; said lateral trackshaving end means supported on spaced longitudinal tracks; a partialspherical conversion head and a rotating milling cutter supported onsaid axis of said conversion head movably mounted on said lateral tracksand a first moving means connected to said conversion head; a secondmoving means connected to said lateral tracks to move said lateraltracks along said longitudinal tracks; and, said cutter being adapted tocut said low-density fiber glass material when said cutter is movedrelative to said low-density fiber glass material.
 19. The machinerecited in claim 18 wherein said lateral tracks are fixed to saidmachine and said lateral track longitudinal ends are movably supportedon said longitudinal tracks; a first motor means on said conversationhead for moving along said lateral tracks laterally relative to saidmachine thereby cutting said material laterally; and, a milling cutterbeing adapted to move with said lateral tracks thereby cutting saidmaterial longitudinally.
 20. The machine recited in claim 19 whereinsaid lateral track has end means attached thereto supporting saidlateral tracks on said longitudinal tracks.
 21. The machine recited inclaim 20 wherein a second motor means is a gear motor having an outputshaft connected to said milling cutter.
 22. The machine recited in claim21 wherein said fiberglass material is supported on a table.
 23. Themachine recited in claim 22 wherein said conversion head is adapted tochannel an airflow to remove waste material during said milling cutteroperation.
 24. The machine recited in claim 23 wherein said lateraltrack has multiple conversion heads and milling cutters movably mountedthere upon.
 25. The machine recited in claim 24 wherein saidlongitudinal tracks have multiple lateral tracks with said attached endmeans being supported on said longitudinal tracks.
 26. The machinerecited in claim 25 wherein said multiple lateral tracks have a crossbrace attached there between forming a gantry; and, said gantry beinghinged to swing upwards by hinge means attached at one end of saidlateral tracks.